Complete service repair manual with Electrical Wiring Diagrams for Komatsu 95E Series Diesel Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu 95E Series Diesel Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEN01966-15 - 95E-5 Series Diesel Engine Shop Manual.pdf
SEN04357-00 - 95E-5 Series (KOHAG SPEC.) Diesel Engine Shop Manual.pdf
SEN06060-01 - 95E-6 Series Diesel Engine Shop Manual.pdf

Total Pages: 1,041 pages
File Format: PDF
Language: English

MAIN SECTIONS
01 GENERAL ....... 01-1
11 STRUCTURE AND FUNCTION .... 11-1
12 TESTING AND ADJUSTING ..... 12-1
13 DISASSEMBLY AND ASSEMBLY .... 13-1
14 MAINTENANCE STANDARD ..... 14-1
15 REPAIR AND REPLACEMENT OF PARTS ... 15-1

SEN01966-15 - 95E-5 Series Diesel Engine Shop Manual......2
  COVER......2
  00 Index and foreword......0
    Index......4
      Composition of shop manual......5
      Table of contents......6
    Foreword and general information......12
      Safety notice......13
      How to read the shop manual......18
      Explanation of terms for maintenance standard......20
      Handling of electric equipment and hydraulic component......22
      Handling of connectors newly used for engines......31
      How to read electric wire code......34
      Precautions when carrying out operation......37
      Method of disassembling and connecting push-pull type coupler......40
      Standard tightening torque table......43
      Conversion table......47
  01 Specification......0
    Specification and technical data......54
      General information......55
      Specifications......57
      General view......65
      Weight table......74
      Engine performance curves......75
  10 Structure, function and maintenance standard......0
    Structure, function and maintenance standard, Part 1......84
      General structure......87
      Air intake and exhaust unit......89
      Air cleaner......91
      Turbocharger......93
      Muffler......96
      Cylinder head......97
      Cylinder block......99
      Cylinder......102
      Main moving parts......103
      Crankshaft......105
      Camshaft......106
      Piston, piston ring and piston pin......107
      Connecting rod......108
      Flywheel and flywheel housing......111
      Timing gear......113
      Valve system......117
      Valve, valve guide......119
      Rocker arm shaft, push rod and tappet......120
    Structure, function and maintenance standard, Part 2......122
      Lubrication system diagram......124
      Oil pump......125
      Regulator valve......127
      Oil filter......128
      Fuel system diagram......130
      Supply pump......131
      Fuel injection nozzle......133
      Fuel filter......134
      Common rail......135
      Various sensor......137
      Cooling system diagram......139
      Water pump......140
      Cooling fan drive and thermostat......143
      Starting and charging system electrical circuit diagram......147
      Alternator......148
      Starting motor......152
      Starting aid......154
      Engine controller......155
  20 Standard value table......0
    Standard service value table......158
      Standard service value table for testing, adjusting, and troubleshooting......159
      Running-in standard and performance test standard......165
  30 Testing and adjusting......0
    Testing and adjusting......174
      Testing and adjusting tools list......176
      Sketches of special tools......178
      Measuring intake air pressure......179
      Testing exhaust temperature......180
      Adjusting valve clearance......181
      Testing compression pressure......183
      Testing blow-by pressure......185
      Testing oil pressure......186
      Handling fuel system parts......187
      Releasing residual pressure in fuel system......187
      Testing fuel pressure......188
      Reduced cylinder mode operation......189
      No-injection cranking......189
      Testing leakage from pressure limiter and return rate from injector......190
      Bleeding air from fuel circuit......193
      Testing fuel system for leakage......195
      Testing and adjusting alternator belt tension......196
      Handling controller voltage circuit......197
  40 Troubleshooting......0
    General information on troubleshooting......200
      Points on troubleshooting......201
      Error code and failure code table......203
      Information in troubleshooting table......205
      Connection table for connector pin numbers......207
      T- branch box and T- branch adapter table......243
    Troubleshooting of electrical system (E-mode), Part 1......248
      E-1 Code [111/CA111] ECM Critical Internal Failure......251
      E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error......254
      E-3 Code [122/CA122] Charge Air Press Sensor High Error......255
      E-4 Code [123/CA123] Charge Air Press Sensor Low Error......257
      E-5 Code [131/CA131] Throttle Sensor High Error......258
      E-6 Code [132/CA132] Throttle Sensor Low Error......261
      E-7 Code [144/CA144] Coolant Temp. Sensor High Error......263
      E-8 Code [145/CA145] Coolant Temp. Sensor Low Error......265
      E-9 Code [153/CA153] Charge Air Temp. Sensor High Error......267
      E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error......269
      E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error......270
      E-12 Code [221/CA221] Ambient Air Press. Sensor High Error......271
      E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error......273
      E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error......274
      E-15 Code [234/CA234] Eng. Overspeed......275
      E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error......277
      E-17 Code [271/CA271] IMV Short Error......279
      E-18 Code [272/CA272] IMV Open Error......281
      E-19 Code [322/CA322] Injector #1 System Open/Short Error......283
      E-20 Code [324/CA324] Injector #3 System Open/Short Error......285
      E-21 Code [331/CA331] Injector #2 System Open/Short Error......287
      E-22 Code [332/CA332] Injector #4 System Open/Short Error......289
      E-23 Code [351/CA351] INJ. Drive Circuit Error......291
      E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error......294
      E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error......295
      E-26 Code [431/CA431] Idle Validation SW Low error......297
      E-27 Code [432/CA432] Idle Validation Process error......297
      E-28 Code [435/CA435] Abnormality in engine oil pressure switch......298
      E-29 Code [441/CA441] Battery voltage low error......299
      E-30 Code [442/CA442] Battery voltage high error......299
    Troubleshooting of electrical system (E-mode), Part 2......302
      E-31 Code [449/CA449] Rail Press. Very High Error......304
      E-32 Code [451/CA451] Rail Press. Sensor High Error......305
      E-33 Code [452/CA452] Rail Press. Sensor Low Error......307
      E-34 Code [553/CA553] Rail Press. High Error......308
      E-35 Code [559/CA559] Rail Press. Low Error......309
      E-36 Code [689/CA689] Eng. Ne Speed Sensor Error......313
      E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error......315
      E-38 Code [757/CA757] All Persistent Data Lost Error......316
      E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error......317
      E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error......319
      E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error......320
      E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......323
      E-43 Code [2249/CA2249] Rail Press. Very Low Error......324
      E-44 Code [2311/CA2311] Abnormality in IMV solenoid......325
      E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error......326
      E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error......327
      E-47 Code [(---)/B@BAZG] Eng. Oil press. Low Speed Derate......329
      E-48 Code [(---)/B@BAZG] Eng. Oil press. Torque Derate......329
      E-49 Code [(---)/B@BCNS] Eng. Overheat......330
    Troubleshooting of mechanical system (S-mode)......332
      Method of using troubleshooting charts......335
      S-1 Starting performance is poor......339
      S-2 Engine does not start......340
      S-3 Engine does not pick up smoothly......343
      S-4 Engine stops during operations......344
      S-5 Engine does not rotate smoothly......345
      S-6 Engine lacks output (or lacks power)......346
      S-7 Exhaust smoke is black (incomplete combustion)......347
      S-8 Oil consumption is excessive (or exhaust smoke is blue)......348
      S-9 Oil becomes contaminated quickly......349
      S-10 Fuel consumption is excessive......350
      S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......351
      S-12 Oil pressure drops......352
      S-13 Oil level rises (Entry of coolant or fuel)......353
      S-14 Coolant temperature becomes too high (overheating)......354
      S-15 Abnormal noise is made......355
      S-16 Vibration is excessive......356
  50 Disassembly and assembly......0
    General information on disassembly and assembly......358
      How to read this manual......359
      Coating materials list......361
      Special tools list......364
      Sketches of special tools......365
    Disassembly and assembly, Part 1......368
      General disassembly of engine......369
    Disassembly and assembly, Part 2......382
      General assembly of engine......383
    Disassembly and assembly, Part 3......400
      Disassembly and assembly procedure for fuel supply pump unit......401
      Disassembly and assembly procedure for oil seal units......403
  90 Repair and replacement of parts......0
    Information related to repair and replacement......406
      Special tool table......407
      Sketches of special tools......409
    Parts related to cylinder head......412
      Part names related to cylinder head......413
      Testing and inspection of cylinder head......414
      Pressure test of cylinder head......416
      Replacement of valve guide......416
      Replacement of valve seat insert......418
      Repair of cylinder head mounting face by grinding......424
      Repair of valve by grinding......425
    Parts related to cylinder block......428
      Part names related to cylinder block......429
      Testing and inspection of cylinder block......430
      Part names related to crankshaft......433
      Testing and inspection of crankshaft......434
      Part names related to connecting rod......435
      Testing and inspection of connecting rod......436
      Replacement of flywheel ring gear......437
      Replacement of crankshaft gear......438
      Replacement of camshaft gear......438
      Replacement of connecting rod small end bushing......439
      Replacement of cam bushing......441
      Cylinder liner (Special part for repair)......443
      Rework drawing for counter bore......444
      Repair of crankshaft by grinding......445
SEN04357-00 - 95E-5 Series (KOHAG SPEC.) Diesel Engine Shop Manual......450
  SEN04357-00 WA90-6, WA100M-6......450
  00 Index and foreword......452
    Index......452
      Composition of shop manual......453
      Table of contents......454
    Foreword and general information......460
      Safety notice......461
      How to read the shop manual......466
      Explanation of terms for maintenance standard......468
      Handling of electric equipment and hydraulic component......470
      Handling of connectors newly used for engines......479
      How to read electric wire code......482
      Precautions when carrying out operation......485
      Method of disassembling and connecting push-pull type coupler......488
      Standard tightening torque table......491
      Conversion table......495
  01 Specification......502
    Specification and technical data......502
      Outline......503
      Specifications......505
      General view......507
      Weight table......510
      Engine performance curves......511
  10 Structure, function and maintenance standard......516
    Structure, function and maintenance standard, Part 1......516
      General structure......519
      Air intake and exhaust system......521
        Air intake and exhaust unit......521
        Turbocharger......523
      Engine unit......527
        Cylinder head......527
        Cylinder block......529
        Cylinder......532
        Main moving parts......533
        Crankshaft......535
        Camshaft......536
        Piston, piston ring and piston pin......537
        Connecting rod......538
        Flywheel and flywheel housing......539
        Timing gear......541
        Valve system......545
        Valve, valve guide......547
        Rocker arm shaft, push rod and tappet......548
    Structure, function and maintenance standard, Part 2......550
      Lubrication system......552
        Lubrication system diagram......552
        Oil pump......553
        Regulator valve......555
        Oil filter......556
      Fuel system......558
        Fuel system diagram......558
        Supply pump......559
        Fuel injection nozzle......561
        Fuel filter......562
        Common rail......563
        Various sensor......565
      Cooling system......567
        Cooling system diagram......567
        Water pump......568
        Cooling fan drive and thermostat......571
      Electrical equipment......575
        Starting and charging system electrical circuit diagram......575
        Alternator......576
        Starting motor......578
        Starting aid......579
        Engine controller......580
  20 Standard value table......582
    Standard service value table......582
      Standard service value table for testing, adjusting, and troubleshooting......583
      Running-in standard and performance test standard......584
  30 Testing and adjusting......588
    Testing and adjusting......588
      Testing and adjusting tools list......590
      Measuring intake air pressure......591
      Testing exhaust temperature......592
      Adjusting valve clearance......593
      Testing compression pressure......595
      Testing blow-by pressure......597
      Testing oil pressure......598
      Handling fuel system parts......599
      Releasing residual pressure in fuel system......599
      Testing fuel pressure......600
      Reduced cylinder mode operation......601
      No-injection cranking......601
      Testing leakage from pressure limiter and return rate from injector......602
      Bleeding air from fuel circuit......605
      Testing fuel system for leakage......607
      Testing and adjusting alternator belt tension......608
      Handling controller voltage circuit......609
  40 Troubleshooting......612
    General information on troubleshooting......612
      Points on troubleshooting......613
      Error code and failure code table......615
      Information in troubleshooting table......617
    Troubleshooting of electrical system (E-mode), Part 1......620
      E-1 Code [111/CA111] ECM Critical Internal Failure......623
      E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error......626
      E-3 Code [122/CA122] Charge Air Press Sensor High Error......627
      E-4 Code [123/CA123] Charge Air Press Sensor Low Error......629
      E-5 Code [131/CA131] Throttle Sensor High Error......630
      E-6 Code [132/CA132] Throttle Sensor Low Error......633
      E-7 Code [144/CA144] Coolant Temp. Sensor High Error......634
      E-8 Code [145/CA145] Coolant Temp. Sensor Low Error......635
      E-9 Code [153/CA153] Charge Air Temp. Sensor High Error......637
      E-10 Code [154/CA154] Charge Air Temp. Sensor Low Error......639
      E-11 Code [187/CA187] Sensor Sup. 2 Volt. Low Error......640
      E-12 Code [221/CA221] Ambient Air Press. Sensor High Error......641
      E-13 Code [222/CA222] Ambient Air Press. Sensor Low Error......643
      E-14 Code [227/CA227] Sensor Sup. 2 Volt. High Error......644
      E-15 Code [234/CA234] Eng. Overspeed......646
      E-16 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error......647
      E-17 Code [271/CA271] IMV Short Error......649
      E-18 Code [272/CA272] IMV Open Error......651
      E-19 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error......653
      E-20 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error......655
      E-21 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error......657
      E-22 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error......659
      E-23 Code [351/CA351] INJ. Drive Circuit Error......661
      E-24 Code [352/CA352] Sensor Sup. 1 Volt. Low Error......664
      E-25 Code [386/CA386] Sensor Sup. 1 Volt. High Error......665
      E-26 Code [431/CA431] Idle Validation SW Low error......667
      E-27 Code [432/CA432] Idle Validation Process error......667
      E-28 Code [435/CA435] Abnormality in engine oil pressure switch......668
      E-29 Code [441/CA441] Battery voltage low error......669
      E-30 Code [442/CA442] Battery voltage high error......669
    Troubleshooting of electrical system (E-mode), Part 2......672
      E-31 Code [449/CA449] Rail Press. Very High Error......674
      E-32 Code [451/CA451] Rail Press. Sensor High Error......675
      E-33 Code [452/CA452] Rail Press. Sensor Low Error......677
      E-34 Code [553/CA553] Rail Press. High Error......678
      E-35 Code [559/CA559] Rail Press. Low Error......679
      E-36 Code [689/CA689] Eng. Ne Speed Sensor Error......683
      E-37 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error......685
      E-38 Code [757/CA757] All Persistent Data Lost Error......686
      E-39 Code [778/CA778] Eng. Bkup Speed Sensor Error......687
      E-40 Code [1633/CA1633] KOMNET Dtalink Timeout Error......689
      E-41 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error......690
      E-42 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......693
      E-43 Code [2249/CA2249] Rail Press. Very Low Error......694
      E-44 Code [2311/CA2311] Abnormality in IMV solenoid......695
      E-45 Code [2555/CA2555] Grid Heater Relay Volt. Low Error......697
      E-46 Code [2556/CA2556] Grid Heater Relay Volt. High Error......699
      E-47 Code [(- - -)/B@BAZG] Eng. Oil press. Low Speed Derate......701
      E-48 Code [(- - -)/B@BAZG] Eng. Oil press. Torque Derate......701
      E-49 Code [(- - -)/B@BCNS] Eng. Overheat......702
    Troubleshooting of mechanical system (S-mode)......704
      Method of using troubleshooting charts......707
      S-1 Starting performance is poor......711
      S-2 Engine does not start......712
      S-3 Engine does not pick up smoothly......715
      S-4 Engine stops during operations......716
      S-5 Engine does not rotate smoothly......717
      S-6 Engine lacks output (or lacks power)......718
      S-7 Exhaust smoke is black (incomplete combustion)......719
      S-8 Oil consumption is excessive (or exhaust smoke is blue)......720
      S-9 Oil becomes contaminated quickly......721
      S-10 Fuel consumption is excessive......722
      S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......723
      S-12 Oil pressure drops......724
      S-13 Oil level rises (Entry of coolant or fuel)......725
      S-14 Coolant temperature becomes too high (overheating)......726
      S-15 Abnormal noise is made......727
      S-16 Vibration is excessive......728
  50 Disassembly and assembly......730
    General information on disassembly and assembly......730
      How to read this manual......731
      Coating materials list......732
      Special tools list......735
    Disassembly and assembly, Part 1......738
      General disassembly of engine......739
    Disassembly and assembly, Part 2......752
      General assembly of engine......753
    Disassembly and assembly, Part 3......770
      Disassembly and assembly procedure for fuel supply pump unit......771
      Disassembly and assembly procedure for oil seal units......773
SEN06060-01 - 95E-6 Series Diesel Engine Shop Manual......776
  COVER......776
  00 Index and foreword ......778
    Index ......779
    Foreword, safety and general information ......782
      Important safety notice ......782
      How to read the shop manual ......789
      Explanation of terms for maintenance standard ......791
      Handling equipment of fuel system devices ......793
      Handling of intake system parts ......794
      Handling of hydraulic equipment ......795
      Method of disconnecting and connecting of push-pull type coupler ......797
      Handling of electrical equipment ......800
      How to read electric wire code ......808
      Precautions when performing operation ......811
      Standard tightening torque table ......816
      List of abbreviation ......822
      Conversion table ......827
  01 Specification ......832
    Table of contents ......833
    General information ......834
      Exhaust gas regulation ......834
    Specifications ......837
      Applicable machines ......837
      Specifications ......838
      General view ......841
      Weight table ......850
      Engine performance curve ......851
  10 Structure and function ......854
    Table of contents ......855
    Components layout ......856
      Components layout drawing ......856
    Intake and exhaust system parts ......858
      Intake and exhaust system layout drawing ......858
      Intake and exhaust system circuit diagram ......860
      Air cleaner ......862
      VFT ......863
      EGR system piping drawing ......867
      EGR system circuit diagram ......869
      EGR valve ......870
      EGR cooler ......872
      KCCV layout drawing ......874
      KCCV ventilator ......876
      KDOC muffler ......880
    Engine main body parts ......882
      General structure ......882
      Cylinder head ......886
      Cylinder block ......888
      Main moving parts ......890
      Timing gear ......893
      Front cover ......895
      Valve system ......896
      Flywheel and flywheel housing ......898
    Lubrication system ......899
      Lubrication system chart ......899
      Oil pump ......901
      Oil filter ......903
      Oil cooler ......905
      Oil pan ......906
    Fuel system ......907
      Fuel system parts layout drawing ......907
      Fuel system circuit diagram ......909
      Prefilter ......910
      Main filter ......911
      Supply pump ......912
      Common rail ......913
      Injector ......914
    Cooling system ......918
      Cooling system parts layout drawing ......918
      Cooling system chart ......919
      Drive pulley ......920
      Water pump ......922
      Thermostat and jiggle valve ......923
    Electrical equipment ......927
      Alternator ......927
      Starting motor ......932
      Intake air heater ......936
      Engine harness ......937
      Engine controller ......939
      Sensor ......945
  20 Standard value tables ......954
    Table of contents ......955
    Standard service value table ......956
      Standard value table for engine ......956
      Running-in standard and performance test standard ......960
  50 Disassembly and assembly ......964
    Table of contents ......965
    Related information on disassembly and assembly ......966
      How to read this manual ......966
      Coating materials list ......968
      Special tools list ......972
      Sketches of special tools ......973
    Disassembly and assembly ......974
      General disassembly of engine ......974
      General assembly of engine ......989
      Removal and installation procedure of supply pump unit alone ......1012
      Engine front oil seal replacement procedure ......1015
      Engine rear oil seal replacement procedure ......1016
  60 Maintenance standard ......1018
    Table of contents ......1019
    Intake and exhaust system parts ......1020
      VFT ......1020
    Engine main body parts ......1021
      Cylinder head ......1021
      Cylinder block ......1023
      Crankshaft ......1025
      Piston ......1026
      Connecting rod ......1027
      Timing gear ......1028
      Camshaft ......1029
      Valve system ......1030
      Valve and valve guide ......1031
      Rocker arm shaft, push rod, and tappet ......1032
      Flywheel and flywheel housing ......1033
    Lubrication system ......1035
      Oil pump ......1035
    Cooling system ......1037
      Water pump ......1037
  INDEX......1038

Komatsu 95E Series Diesel Engine Repair Service Manuals